A Complete Guide to Hacksaws

A hacksaw is a type of hand tool designed specifically for cutting through materials such as plastic, steel, and other metals. They are a variant of the traditional hand saw, typically used for cutting wood, and have become a staple tool for professionals and hobbyists alike.

Hacksaws supply firm and precise cutting power, ideal for a wide range of projects and applications. Physically, they are characterised by their distinctive adjustable frame shaped like the letter ‘D’, which holds the blades under tension.

Professionals including plumbers, electricians and mechanics regularly make use of hacksaws when carrying out their day-to-day tasks. Some of the most common uses for hacksaws include:

• Sawing pipes
• Shaping metal sheeting
• Cutting plastic

As with any other tool, strong focus and attention to detail are key to ensuring safety when using a hacksaw. Here are some top tips for using a hacksaw safely:

• Make sure you have chosen the right blade for the task
• Ensure the blade is mounted in the correct direction, facing forwards
• Check that the blade is properly secured to the frame
• Firmly secure the object you are cutting, using a vice, for example
• Saw vigorously, taking care to direct the cutting movements away from your body

How to Change a Hacksaw Blade

Changing a hacksaw blade is a straightforward process, regardless of whether you are using a senior or junior model. Below is a handy step-by-step guide detailing the process:

• Depending on the model of hacksaw you have, either apply the fasten-release mechanism or turn the wing nut to loosen the current blade
• Carefully slide out the current blade
• Insert the fresh blade onto the retaining pins within the handle
• Either tighten the wing nut or reapply the fasten-release mechanism
• Conduct a test cut on a piece of scrap metal to ensure the new blade is safe and properly secured

How to Maintain a Hacksaw

Regularly maintaining your hacksaw and keeping it in good condition will not only ensure a quality cut but it will also lessen the safety risk associated with using the tool. When conducting hacksaw maintenance, consider the following fundamentals:

• You should regularly inspect hacksaw blades for signs of damage including warping or blunting
• If blades do show signs of wear and tear, replace them
• Apply oil or lubricant to the blade to prevent overheating when cutting
• Minimise the risk of breakage when cutting harder materials by cutting more slowly
• Regularly clean hacksaw blades to keep them in good condition for longer

Many different brands and manufacturers supply hacksaws, each best suited to varying applications. The following are just a few examples of popular brands.

How Many Teeth Per Inch on a Hacksaw Blade?

Hacksaw blades are distinguished by the pitch (frequency) of their teeth. These can vary from three relatively large teeth per inch (TPI) through to 32 TPI, ideal for very fine cutting. As a general rule, the larger the blade, the lower the number of teeth per inch.

How Thick is a Hacksaw Blade?

A standard 12-inch (300mm) hacksaw blade will typically be 0.63mm thick.

How Do You Cut Aluminium with a Hacksaw?

Although it is relatively soft, aluminium can be a difficult metal to cut because the shavings tend to accumulate and stick to the blade. Therefore, to achieve an effective cut, it is advisable to choose larger blades with lower TPI. You can also apply oil or lubricant for a smoother cut.

What are Hacksaw Blades Made from?

Hacksaw blades are typically made from high-speed steel (HSS), a tough, abrasion-resistant variety of steel. HSS is widely used to make tools, cutting blades and drill bits thanks to its strength, accuracy, and resistance to warpage and breakage.

Why are Hacksaw Blades Made with Different-Sized Teeth?

Different-sized teeth provide varying levels of cutting power. Large blades with fewer teeth are better suited to tough materials, while smaller blades with a greater number of teeth are designed for finer work.

Who Invented the Hacksaw and When?

Various types of saws have been used to cut materials for centuries, but the modern hacksaw owes a great deal to Max Flower-Nash Clemson. He conducted a series of experiments in the 1880s looking at ways to increase the efficiency of saw blades via heat treatments and by changing the size and number of embedded teeth. He was eventually granted an official patent for his improvements.

Does a Hacksaw Cut on the Push or the Pull?

Hacksaw blades should be mounted in their frames with the teeth facing forwards. They are designed so that the blade will cut on the push – the forward stroke – rather than the pull, or backwards stroke. The correct orientation for mounting will sometimes be indicated by an arrow marked on the blade.